2x500 MW, NNTPP, Neyveli CONTRACT · PDF file2x500 MW, NNTPP, Neyveli CONTRACT SPECIFICATION...

2x500 MW, NNTPP, Neyveli

CONTRACT SPECIFICATION STEAM TURBINE GENERATOR PACKAGE – NTA2

TG Vol-IV, Section-08, UPS & Battery, Elect. – NTA2 57

a) All equipment and materials will be designed, manufactured and

tested in accordance with the latest applicable Indian Standards (IS)

except where modified and/or supplemented by this specification. In

case Indian Standards are not available for any equipment, Standards

issued by IEC/BS/VDE/IEEE/NEMA or equivalent will be applicable.

b) Equipment and materials conforming to any other standard which

ensures equal or better quality may be accepted. In such case, copies

of the English version of the standard adopted will be submitted .

c) The electrical installation will meet the requirements of Indian

Electricity Rules as amended up to date and relevant IS Codes of

Practice. In addition, other rules or regulations applicable to the work

will be followed. In case of any discrepancy, the more restrictive rule

will be binding.

2.2 Annexures

2.2.1 All annexures appended to this specification will form part of this specification

and supplement the requirements specified herein.

2.2.2 This specification will be read and construed in conjunction with the drawings

and annexures to determine the scope of work and terminal points.

2.3 Completeness of supply

2.3.1 It is not the intent to specify completely herein all details of the equipment.

Nevertheless, the equipment will be complete and operative in all aspects and

will conform to the highest standard of engineering, design and workmanship.

2.3.2 Any material or accessory which may not have been specifically mentioned but

which is necessary or usual for satisfactory and trouble free operation and

maintenance of the equipment will be furnished.

2.3.3 The contractor will supply all brand new equipment and accessories as specified

herein.

2.4 Guaranteed Performance

2.4.1 The proposal data sheets given in another volume of this package specification

will be filled in without any ambiguity by typing in appropriate place on each

page.

2.5 Drawing Approval

2.5.1 Before starting manufacture of any equipment, the contractor will have to take

approval of relevant drawings and data from Owner/Consultant in writing.

2.5.2 Any manufacture done prior to the approval of drawings/data will be rectified in

accordance with the approved drawings/data by the contractor at his own cost

and the equipment will be supplied within the stipulated period.

2.6 Design Criteria

2.6.1 Design Basis

a) UPS System provides a regulated and uninterrupted single phase A.C.

power, within specified tolerances, to critical station loads during

normal and emergency operation.

THIS IS A PART OF TECHNICAL SPECIFICATION NO.PE-TS-402-155A-A001

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TG Vol-IV, Section-08, UPS & Battery, Elect. – NTA2 Page 158

b) The UPS system excluding its battery will be installed indoors in A.C.

environment.

c) UPS system will be compatible for satisfactory and well-coordinated

operation with other related equipment as well as with input and output

systems.

d) Energizing or de-energizing any portion of the system serviced by the

UPS will not cause output changes which will affect the operation or

integrity of the remaining portions of the system in any way.

e) The equipment will be self-protecting against all A.C. and D.C.

transients, voltage surges, and steady state abnormal voltages and

currents.

f) The circuit protection will be coordinated with UPS short circuit

capacity and protective device characteristics so that a fault on any

circuit will result in minimum loss of function.

g) All non-interrupting components of UPS system will be capable of

withstanding the prevailing short circuit current without damage.

h) All circuit interrupting components will be capable of withstanding and

interrupting the prevailing short circuit currents without damage.

i) For continuous operation at specified ratings, temperature rise of the

various components of UPS system will be limited to the permissible

values stipulated in the relevant standards and/or this specification.

For selecting Battery capacity following data to be considered :

Maximum temperature : 50 °C

Minimum temperature : 8 °C

Battery backup time : 30 minutes

Design margin : 15%

Ageing compensation factor : 1

Reference standard for Battery

Sizing calculation : As per IEEE 446 Standard

k) UPS will have automatic on line battery health checking. It will have

connectivity with the plant DCS status monitoring.

l) The chargers, inverters, static switches, regulating transformers and

voltage stabilizers should be arranged in such a way that any

equipment will be fully isolated for maintenance without affecting in

any way the operation of other panels/ components.

m) In the A.C. Distribution Board, the contractor will provide 10% or

minimum one (1) no. spare feeder of each size and type of the outgoing

feeders.

n) The UPS system supplied will have provision to transfer UPS

parameter/data to DCS (Including SG & TG Integral Control System).


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Necessary data transfer software & hardware will be incorporated in

the system for this.

2.6.2 System Concept

a) 3 nos. independent A.C. power sources are available to the UPS

system. The system is so designed that its load will be served without

interruption as long as one of the above power sources is available

within specified limit of voltage and/or frequency.

The UPS will consist of two physically separate sets of equipment

streams consisting of the following:

i) Two sets of converters to convert incoming 415V, 3 Ph, 50 Hz

A.C. power to suitable D.C.

ii) Two sets of suitable Battery Bank to get charged by the above

referred converter and to feed the inverter described below.

iii) Two sets of inverters to take D.C. input from above referred

converter- Battery assembly output and to produce high quality

240V, 1Ph 50 Hz A.C. output power.

iv) Two sets of static switches, synchronizing circuit to parallel the

above-mentioned Inverter output and bypass stabilized power

stream.

v) One set of standby bypass stream consisting of suitable

transformers, Static voltage regulator etc. to produce regulated

240V, 1 Ph. 50 Hz A.C. power from the 415V, 3 Ph. 50 Hz A.C.

input from Station supply.

vi) One UPS A.C. power distribution board with suitable no. of

outgoing feeders.

Two sets of equipment streams as mentioned above will constitute the UPS

system.

One set of synchronizing equipment and high performance static switch will

parallel the above two streams and common output will be taken to loads

which can accept only single non-redundant power input source.

The system will ensure highest system availability around 99%.

b) Each of the two UPS streams will be of 100% capacity and will

normally work, each sharing 50% load. On failure of any stream, its

load gets automatically transferred to the other inverter through static

transfer switch.

c) If one UPS stream is out of service for any reason then the second UPS

stream will be working with 100% UPS load.

d) Inside each stream on failure of its converter/battery/inverter assembly

the standby A.C. source will back up to supply the 100% UPS load

automatically through static transfer switch.

2.6.3 Layout Criteria

a) The UPS system will be located indoor in Power House operating floor.

The inverter, static switches, chargers and distribution panels will be located in

the UPS room. The batteries will be located in a separate battery room as

shown in enclosed machine location plans.


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The charger, inverters, static switches, regulating transformers & voltage

stabilizers should be arranged in such a way that any equipment can be fully

isolated for maintenance without affecting in any way the operation of other

panels/components.

The equipment of the two UPS streams will be physically isolated with

reasonable space between two installations.

b) Battery room ventilation will be under the scope of the Contractor.

c) Sufficient clear space will be provided for comfortable attending and

removal of individual cells.

d) Sufficient clear space will be kept in the battery room to accommodate

a battery of identical capacity in future.

e) Battery room will be acid proof type.

3 SPECIFIC REQUIREMENTS

3.1 Static Inverter

a) The static inverters will be static type consisting of IGBT PWM type

inverter, static filters, integrated control modules including necessary

oscillators, voltage regulators, current limiting and surge suppression.

b) The inverter equipment will include all necessary circuitry and devices to

conform requirements like voltage regulation, soft start, transient

recovery, protection, automatic synchronisation, wave shaping etc. as

specified herein.

c) Upon transfer of full load, the inverter output voltage will not drop

below 80% of nominal voltage during the first half cycle after transfer

and 90% of nominal voltage in the next half cycle. The recovery to

within ± 2% of voltage will be in less than 50 milli-seconds.

d) On occurrence of a fault in branch circuit, the inverter will be capable of

clearing the highest rated branch circuit fuse in 4 milli-seconds or less.

e) The inverter will be protected against overload, short circuit, 100% loss

of load, as well as excursions, loss or restoration of D.C. input voltage

and synchronising voltage. The overload capacity will be 125% for 10

mins., 150% for 60 secs. and 300% for 4 msecs.

f) The D.C. input current will never exceed twice the full load current

except for a short circuit within the inverter.

g) For any value of the load and load power factor drawn by the equipment

served, the inverter will not impose on D.C. source any voltage

oscillations in excess of 5 volts (RMS total all frequencies) or any

current oscillations in excess of 3 percent (RMS total all frequencies) of

the D.C. current at full load.

h) The inverter will be self protecting against A.C. and D.C. Transients,

voltage surges and steady state abnormal voltage and currents likely to

be encountered in the plant.


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i) Under voltage(u/v), Over voltage(o/v) and earth fault protections will be

provided for UPS (either separate relays or achieved electronically)

3.2 Automatic Synchronisation

a) Inverter equipment will include stable solid state oscillator devices

designed to automatically maintain the inverter output in phase and in

synchronism with the stand-by A.C. source.

b) Facility will be provided for automatic transfer to internal oscillator

operation when the stand-by source frequency is beyond specified limits

and the frequency will be automatically controlled within 50 Hz plus or

minus 0.5 Hz when the inverter operates in this mode.

c) Retransfer to stand-by A.C. source for synchronisation will be automatic

after the stand-by source frequency is restored to permissible limits and

remains within this limit for an adjustable time delay period (up to 5

seconds).

d) Provision will be made for stepless adjustment of synch- disconnect

frequency range from 50 Hz ± 0.5 Hz to 50 Hz ± 2 Hz.

e) Automatic adjustment of phase relationship between inverter output

and stand-by A.C. source will be gradual at a controlled slow rate,

which will not exceed one hertz per second.

3.3 Static Transfer Switch

a) The static transfer switch will be solid-state type using SCR for

automatic/manual transfer of load from "inverter" to "stand-by" source

and vice-versa.

b) Stand-by source can be either of the inverter or A.C. source depending

on whether both the inverters are supplying 50% load each or one of

the inverter is carrying 100% load.

c) The transfer time including sensing will be less than 4 m.secs. Further

the transition will be make- before-break in both directions.

d) The capacity of static transfer switch will be equal to the continuous

full-load capacity of the inverter. The switch will be provided with

protective devices in both normal and alternate power source.

e) Static transfer switch will be furnished with contact to alarm failure of

the alternate source or opening of any fuse protecting the static switch.

f) Static transfer switch will include all necessary circuitry and devices to

meet the functional requirements of transfer initiation, transfer inhibit

and re-transfer back to normal as detailed below :

g) Transfer Initiation

i) The transfer of static switch from normal 'Inverter' position to

'stand-by' position will be initiated by one of the following

causes.

• Inverter failure and UPS system trouble.

• Inverter output voltage failure.

• Manual push button operation.


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ii) The UPS bus will be monitored by two voltage detectors. One

fast acting circuit will be used for detecting a complete and

instantaneous voltage loss while the other slower acting

averaging circuit with adjustable trip level will be employed to

detect voltage deviation beyond selected limits. Both voltage

detector circuits will automatically initiate operation of transfer

switch.

iii) The static switch will automatic transfer the load from inverter

to stand-by source when the maximum I2t capability of the

inverter is reached and when the inverter output drops below

90%.

h) Transfer Inhibit

Automatic or manual transfer from inverter to stand-by A.C. source vice

versa will be inhibited when the inverter frequency is not synchronised

to the alternate source.

i) Retransfer to Normal

i) The return to inverter mode will be manual in all cases.

ii) Manual transfer will be initiated by push button actuation.

3.4 Manual By-pass Switch

a) Manual by-pass switch is used to isolate any static transfer switch for

maintenance or repair without interruption to the UPS load.

b) The switch has also the facility of by-passing both the static transfer

switches during start-up at the option of the operator.

c) Switch contact will be make-before-break type.

d) The switch will have current rating equal to the full load inverter current

and necessary short time load carrying and interrupting capacity to meet

the requirement of UPS system.

e) Breakers may be used instead of By-pass switch maintaining the same

philosophy of operation.

3.5 Battery

a) General

i) The battery will be stationary Lead Acid ‘Plante’ type and will be

suitable for operating satisfactorily in humid and corrosive

atmosphere.

ii) The equipment will comply with the requirement of latest revision

of following standards:

IS:1652 : Specification for Stationary cells and Batteries, Lead Acid type with

plante +ve plates.

BS:6290 : Specification for Stationary cells and Batteries, Lead Acid type with

plante +ve plates

Specification of battery will be as given in Section 7 (Battery & battery charger)

3.6 Float-cum-Boost Charger


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3.6.1 Specification of Float cum booster charger will be as given in Section 7 (Battery

& battery charger)

3.7 Step-down transformer and Static voltage regulator (SVR)

a) A three phase to single phase transformer along with associated voltage

stabilizer will be furnished with the UPS system.

b) The transformer and SVR hall be sized for 100 per cent UPS load and

will coordinate with the largest branch circuit protection device for

feeder short circuit current without sacrificing voltage regulation.

c) The SVR will employ silicon solid state circuitry. It will maintain the

specified output voltage within +/- 1.5% through out the load variation

from 0 to 100% with maximum input voltage variation of +/- 10%. The

make and rating will be subject to Purchaser's approval.

3.8 A.C. Distribution Boards

a) The DB will have one section with MCCB as incomer and will have bus

healthy lamps, volt meter and ammeters. Outgoing feeders to the loads

will be protected by semiconductor fuses with fuse monitoring devices,

MCCBs and feeder ‘ON’ LED indication with glass fuse. Each load will be

fed by two independent feeders terminated into a change over switch at

the load point. The gland plate of the distribution board will be non-

magnetic type having thickness 3mm.

Interposing relays / transducers /potential free contacts required for

DCS (Including SG & TG Integral Control System) system will be

mounted on the UPS distribution board.

b) The distribution boards will be fixed type, of modular design in

freestanding gasketted sheet steel enclosure conforming to IP-54. Sheet

steel thickness will be 2 mm minimum.

c) Each module will be housed in a separate compartment complete with

individual front access door. Working height will be limited to 1800 mm

from floor level.

d) A full height vertical cable alley will be provided in each panel to

facilitate module wiring. The alley will be liberally sized and will have

removable cover at the front. Removable back covers will be provided at

the back of the panels.

e) Switches will be double pole, air break, heavy duty type, capable of

safely making and breaking the full load current of associate circuit.

f) Switch handle will have position indicator and provision of padlocking in

ON & OFF positions. Further it will be interlocked with access door for

safety.

g) Fuses will be HRC, preferably link type, design to permit easy & safe

replacement. 20% spare feeders will be provided in the DB. Visible

indication will be provided for indication of fuse.

h) Provision will be made for giving 2 feeders to NTA 1 and four (4)

feeders to NTA 3, besides own requirements.


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3.9 UPS Cabinets/Enclosures

a) The UPS system components will be housed in a sheet steel

freestanding IP-31 enclosure with all access from the front. Sheet steel

thickness will be 2 mm minimum.

b) The enclosure will consist of vertical cabinets housing modules in rack

type sub-assemblies, connected mechanically and electrically to form a

rigid, self-supporting, metal enclosed structure.

c) The modular units will be mounted in pull out and/or swing trays. Each

module will be capable of being easily removed to provide for the ready

inspection of major solid-state devices.

d) Vertical wiring trough will be provided for the entire height of the UPS

cabinet. Cable entry will be from bottom only.

e) Adequate ventilating louvers and screens will be provided. The top of

the panel will be protected by a suitable drip cover to prevent entrance

of falling liquid and foreign material.

f) If the equipment supplied requires forced air cooling, the cooling system

furnished will meet the following requirement :

i) Two (2) nos. 100% cooling fans will be provided for each vertical

panel.

ii) Completely independent duplicate protection, control and wiring

systems will be provided for the cooling fans for redundancy.

iii) The cooling fans will be powered from the output of the

associated inverter. Normally one fan will be running while the

other is on stand-by.

iv) Each cooling fan will be equipped with an airflow switch having an

alarm contact that closes upon failure of airflow.

3.10 Alarms

a) Solid state audio-visual annunciation system will be provided for

inverters, static transfer switch, battery, battery charger.

b) Alarm facia will be provided on each charger and inverter panel,

complete with proper actuating devices, circuitry and legends.

c) The arrangement will be such that on occurrence of a fault the

corresponding window will light up and stays lighted until the fault is

cleared and reset button pressed.

d) Each time a window lights up a master relay will get energized to

provide group alarm signals for remote DCS alarm system.

e) The requirements of indication/metering/alarms are given in the annexure

-B

f) Alarm contacts will be rated 0.5 A at 220 V DC and 5A at 240 V A.C.

g) Electrically independent, potential free alarm contacts for each of the

points mentioned in Annexure-B will be wired up to the terminal block

for Purchaser's use.


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DCS Interface

Suitable soft link to be provided for interfacing with DCS for monitoring

and control.

3.11 Lamp / Space Heaters / Receptacles

a) The panels will be provided with :

i) Internal illumination lamp with door switch.

ii) Space heater with thermostat control.

iii) 3-pin 6A receptacle with plug.

b) Lamp, heater and receptacle circuits will have individual switch fuse

units.

3.12 Wiring / Cabling

a) The panels will be completely wired up. All wiring will be done with

flexible, 1100V grade, PVC insulated wires with stranded 2.5 Sq.mm

copper conductors and routed through wiring troughs. Each wire will be

ferruled by plastic tube with indelible ink print at both end having

terminal block No., terminal number as per approved wiring diagram.

b) Panels will have removable 3mm. gland plate for cable entry. All

incoming/outgoing cables will be terminated in suitable terminal block.

c) Control terminal blocks will be box-clamp type, minimum 10 Sq.mm.

20% spare terminals will be furnished.

3.13 Nameplate

a) Engraved nameplates will be provided for each panel and for each

equipment/device mounted on it.

b) The material will be anodised aluminium / lamicoid, 3 mm thick, with

white letters on black background.

c) Nameplates will be held by self-tapping screws. The size of nameplates

will be approximately 20 mm x 75 mm for equipment and 40 mm x 150

mm for panels.

d) Nameplates for panels will be provided both on the front and rear.

e) Control and meter selection switches will have integral nameplates.

Nameplates for all other devices will be located below the respective

devices.

f) Instruments and devices mounted on the face of the panels will also be

identified on the rear with the instrument/device number. The number

may be painted on or adjacent to the instrument or device case.

g) Caution notice on suitable metal plate will be affixed at the back of each

panel.

3.14 Grounding

a) Normal 3-phase A.C power supply will be grounded at the source. For

grounding other than this, isolation transformer will be furnished with

the U.P.S.


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b) The inverter D.C. input and A.C. output will be electrically isolated from

each other and from cabinet ground.

c) Panels will have fully rated ground bus with two ground terminals, one

at each end.

d) Each terminal will comprise two-bolt drilling M10 G.I. bolts and nuts to

receive Purchaser's ground connection of 50 x 6 mm G.S. flat.

e) Separate electronic grounding will be provided for each UPS system.

3.15 Tropical protection

a) All equipment accessories and wiring will have fungus protection,

involving special treatment of insulation and metal against fungus

insects and corrosion.

b) Screens of corrosion resistant material will be furnished on all ventilating

louvers to prevent the entrance of insects.

3.16 Painting

a) The panels will be finished in light grey shade (shade 631 of IS-5) with

two coats of synthetic enamel paint. The panels will have a matt finish

to prevent any glare from surface due to illumination.

4 TESTS

All equipment and components thereof will be subject to shop tests as per

relevant IEC/BIS Standards. The tests will include, but will not be limited to :

4.1 Tests on Battery

4.1.1 Tests on battery will be as indicated in Section 7 (Battery & battery charger)

4.2 Tests on battery charger

4.2.1 Tests on battery charger will be as indicated in Section 7 (Battery & battery

charger)

4.3 Tests on UPS System

a) Type & routine test for various components.

b) Burning test on PCBS - Assembled PCBS will be tested at 70 Deg.C for

72 hours in loaded condition.

c) Rapid temperature cycling test at 70 Deg.C and 0 Deg.C for 30 minutes

at each temperature - 5 such cycles.

d) Functional tests to demonstrate compliance with all specified

requirements and published. Specifications such as frequency,

regulation, voltage regulation, current limiting, fuse clearing capability of

inverters, demonstration of phase and frequency control of inverter for

synchronisation with range of adjustments transfer and retransfer of

static switches under influence of under voltage and over current, tests

on chargers, batteries and other system component to confirm

compliance with specification.

4.4 TYPE TEST


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4.4.1 Type test certificates of any equipment will be furnished, if so desired by

the Purchaser. Otherwise, the equipment will have to be type tested, free of

charge, to prove the design.

5 DRAWINGS, DATA & MANUALS

5.1 Drawings, data & manuals to be submitted.

5.1.1 Technical data sheet (in the specification format)

5.1.2 UPS panels, Battery Charger and Battery layout drawing with dimensions.

5.1.3 General Arrangement drawing of UPS panels.

5.1.4 Bill of Material.

5.1.5 Schematic drawing of UPS circuits.

5.1.6 Battery cell voltage characteristics and data for different discharge rates.

5.1.7 Technical leaflets on :

a) UPS System

b) Battery

c) Battery charger

d) Inverter

e) Static Switch

f) Manual bypass Switch

5.1.8 Duty cycle diagram and battery sizing calculation in the format of IEEE Standard.

5.1.9 Sizing calculation of UPS system, charger main equipment, viz. SCRs, rectifier

transformers etc.

5.1.10 Type test certificates for similar equipment.

5.2 To be submitted after Award of Contract

5.2.1 Manufacturer’s Quality approval plan & technical data sheet

5.2.2 Dimensional UPS, battery layout diagram in plan & section.

5.2.3 Connection details of take-off terminals.

5.2.4 Dimensional general arrangement drawings of UPS, battery charger, battery

clearly showing device dispositions, cable entry, space requirement, etc.

5.2.5 Sectional views of UPS System panels.

5.2.6 Panel foundation plan and loading.

5.2.7 UPS system schematics and wiring diagrams.

5.2.8 Test reports

5.2.9 Detailed bill of materials.

5.2.10 Any other relevant drawing or data necessary for satisfactory installation,

operation, and maintenance.

5.2.11 Cable schedule & Inter-connection charts.

5.2.12 Instruction manuals of UPS system

The manual will clearly indicate method of installation, check-ups, and tests to

be carried out before commissioning of the equipment.


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5.3 The contractor may note that the drawings, data and manuals listed above are

minimum requirement only. Contractor will ensure that all other necessary

write-ups, curves and information required to fully describe the equipment are

submitted .

6 SPECIAL TOOLS AND TACKLE

6.1 The contractor will quote any special tools and tackles needed for his

equipment or stated herein.

7 RATINGS & REQUIREMENTS

7.1 STATIC INVERTER

7.1.1 Application : UPS System for control system, DCS and other essential loads

7.1.2 Type : static IGBT PWM type

7.1.3 Duty : Continuous

7.1.4 Enclosure : Sheet steel, IP31

7.1.5 Cooling : Natural convection or forced cooling using redundant fans.

7.1.6 Ambient temperature : 50 Deg.C maximum, 8 Deg. C minimum

7.1.7 Inverter capacity (min) : 100 KVA

7.1.8 Overload capacity : 300% for 4 m secs.

150% for 60 secs

125% for 10 mins

110% for continuous

7.1.9 Voltage

a) Inverter input, Battery output : To be decided by the contractor

b) Nominal output : 240 V, 50 Hz, 1-phase

7.1.10 Voltage Regulation :

a) Steady state (0-100% load

at all input voltages and all

power factors)

: ± 1.5%

b) Transient voltage

(On application or removal

of 100% load)

: ± 10%

c) Time to recover from

transient to normal voltage

: 50 milliseconds.


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7.1.11 Wave form :

a) Nominal frequency : 50 Hz

b) Frequency range for all

conditions of input

supplies, loads and

temperature occurring

simultaneous or in any

combination (automatically

controlled)

: ± 0.05 Hz.

c) Synchronisation limits (for

maintenance of

synchronism between

inverter and standby A.C

source)

: 49 Hz to 51 Hz (factory set)

d) Field adjustment range for

(c) above

: 50+_ 0.05 Hz to 50+_ 2 Hz

e) Total Harmonic Content : 5% maximum at rated load

f) Harmonic content for any

single harmonic

: 3% maximum

7.1.12 Rated output current at rated output voltage with current limit not operating

a) Current : 200%

b) Duration : 100 milliseconds.

7.1.13 Efficiency at full load : 90% or better. (Watt output/watt input)

7.1.14 SCR derating from peak voltage and peak rating : 50%

7.1.15 Short time rating : 1 second for short circuit at inverter output terminals

7.2 STATIC SWITCH

7.2.1 Type : Solid-state, SCR


7.2.3 Enclosure : Sheet Steel, IP31

7.2.4 Cooling : Natural convection or forced cooling--using redundant fans

7.2.5 Ambient Temperature : 50 Deg.C

7.2.6 Capacity

a) Continuous : Equal to full load capacity of the inverter.

b) Overload : 300% for 4 m secs.

150% for 60 secs

125% for 10 mins

110% for continuous


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c) Peak : 1000% of continuous rating for 5 cycle.

7.2.7 Normal Voltage : 240V, 50 Hz, 1-phase.

7.2.8 Transient Voltage Tolerance : 340V peak above the nominal line voltage.

7.2.9 Transfer Time : less than 4 m secs.

7.2.10 Short time rating : Short circuit rating of the inverter for 1 second and

150% of Full load current for 2 minutes.

7.3 MANUAL BY-PASS SWITCH/BREAKER

7.3.1 Type : Maintained, make before break.

7.3.2 Voltage : 600V

7.3.3 Rated Current : To meet the requirement as specified in clause no.:

7.3.4 Short time rating : Short circuit rating of the inverter for 1 second and

150% of Full load current for 2 minutes.

7.4 BATTERY

7.4.1 Application : UPS Battery

7.4.2 Ambient Temperature :

a) Maximum : 50 Deg.C

b) Minimum : 8 Deg.C.

7.4.3 Type : Lead acid ‘Plante’ type

7.4.4 Nos. of Cells per Battery : Min 180

7.4.5 Battery nominal voltage : 360 V above

7.4.6 Battery capacity in AH at 27 °C for 5 hr. discharge and end cell voltage of

1.1 Volt/Cell : Contractor to compute considering 100% UPS

load for 30 minutes. For 10 hrs. discharge end cell voltage will be 1.85v/cell for Lead

Acid type.

7.4.7 Method of working

a) Float charge (Normal) : 2.18 Volt / Cell

b) Boost charge : 2.75 Volts/Cell (After complete discharge)

7.4.8 Mounting : Wooden racks

7.4.9 Connection : Cables

7.4.10 Battery Size (AH Capacity) : 500 AH (Minimum)

7.5 BATTERY CHARGER

7.5.1 Charger : Float + Float-cum-Boost

7.5.2 Type : Solid-state, full wave, fully controlled. 3 Phase Bridge.



7.5.5 Cooling : Natural convection or forced cooling using redundant fans.

7.5.6 Ambient Temperature : 50 Deg.C

7.5.7 A.C. input :

a) Supply : 415V, 3-phase ,50 Hz, 3 wire


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b) Voltage variation : ±10%

c) Frequency variation : ± 5%

d) Combined volt frequency

variation : 10% (absolute sum)

e) Short-circuit level : 50 KA

f) System earthing : Unearthed

7.5.8 D.C. output : 100% UPS load plus restoring fully discharged

battery to full charge condition in 8 hours.

7.5.9 Blocking Diode, Peak inverse

voltage : 800 V (minimum)

7.5.10 Performance Requirement

a) The output voltage of the charger will be regulated within ± 1% of the set

value for any load variation from 0 to 100% and A.C input voltage and

frequency variation as indicated above in 5.07.00

b) The ripple content in charger D.C. output will be limited to less than ±

1% with battery and less than ± 2% without battery.

7.6 DISTRIBUTION BOARDS

7.6.1 Type : Fixed, Modular.


7.6.3 Mounting : Free standing ( can be attended from both front & back)


Page 435 of 495




ANNEXURE -1

THE ALARM POINTS TO BE PROVIDED ON UPS

SL. NO. UPS ALARMS

1.0 AC SUPPLY FAILURE

2.0 DC VOLTAGE LOW

3.0 DC VOLTAGE HIGH

4.0 DC SYSTEM GROUND

5.0 CHARGER OVERLOAD

6.0 SCR FUSE BLOWN

7.0 FILTER FUSE BLOWN

8.0 DC OUTPUT FUSE BLOWN

9.0 FLOAT BUS OVER / UNDER VOLTAGE

10.0 BOOST BUS OVER VOLTAGE

11.0 BOOST OVER CURRENT FOR EACH CHARGER

12.0 FAILURE OF TYRISTOR / DIODES FOR EACH CHARGER

13.0 FAILURE OF BLOCKING DIODES

14.0 OUTPUT MCCB OPEN FOR EACH CHARGER

15.0 BATTERY MCCB OPEN

16.0 BATTERY CHARGING/DISCHARGING

LED LAMPS INDICATIONS IN FCBC CUBICLE

1.0 FLOAT CUM BOOST CHARGER

2.0 MAINS AC AVAILABLE

3.0 DC OUTPUT AVAILABLE

4.0 CHARGER IN FLOAT MODE

5.0 CHARGER IN BOOST MODE

6.0 CHARGER TRIPPED ON FAULT

7.0 SELECTED FOR RESERVE OPERATION

INDICATING METERS

ALL INDICATING METERS WILL BE 96x96 mm SWITCHBOARD TYPE, WITH 250 DEG.,

ANTIGLARE GLASS, ±2% ACCURACY WITH ZERO ADJUSTER ON THE FRONT.


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TG Vol-IV, Section-08, UPS & Battery, Elect. – NTA2 3

ANNEXURE -2

SET OF ACCESSORIES TO BE PROVIDED FOR EACH BATTERY BANK

SL. NO. ACCESSORIES/DEVICES QUANTITY (Nos.)

1.0 HYDROMETER 2 NOS.

2.0 SET OF HYDROMETER SYRINGES SUITABLE FOR THE

VENT HOLES IN DIFFERENT CELLS

2 NOS.

3.0 THERMOMETER FOR MEASURING ELECTROLYTE

TEMPERATURE

5 NOS.

4.0 SPECIFIC GRAVITY CORRECTION CHARTS 2 NOS.

5.0 WALL MOUNTING TYPE HOLDER FOR HYDROMETER AND

THERMOMETER

2 NOS.

6.0 CELL TESTING VOLTMETER (3-0-3 V) 2 NOS.

7.0 ALKALI MIXING JAR 1 NO.

8.0 ACID MIXING JAR 1 NO.

9.0 RUBBER APRON 2 NOS.

10.0 PAIR OF RUBBER GLOVES 2 NOS.

11.0 SET OF SPANNERS 2 NOS.

12.0 “NO SMOKING” NOTICE 2 NOS.

13.0 GOGGLES (INDUSTRIAL) 2 NOS.

14.0 INSTRUCTION CARD 10 NOS.

IN ADDITION TO THE ABOVE, ONE (1) NO. MINIMUM AND MAXIMUM TEMPERATURE

INDICATOR WILL BE SUPPLIED.


Page 437 of 495

2x500 MW, NNTPS, Neyveli

CONTRACT SPECIFICATION

STEAM TURBINE GENERATOR PACKAGE - NTA2

TG, Vol-III, C&I-NTA2 Page 20

5. DESIGN CRITERIA

This section covers the general design criteria to be adopted in designing the Control & Instrumentation system for the TG Package.

5.1 General Requirements

5.1.1 Ambient Conditions

Instruments, devices and equipment for location in outdoor / indoor / air-conditioned areas shall be designed to suit the environmental conditions indicated below and shall be suitable for continuous operation in the operating environment of a Lignite fired Power plant and also during periods of air conditioning failure without any loss of function, or departure from the specification requirements covered under this specification.

Table 5.1

Protection Class Requirement

Ambient

Temperature

(outside

temperature)

Pressure Relative

Humidity Atmosphere

Required

Protection class

of panels

/cabinets /desks

to be provided

by Contractor

Outdoor Location

55 *C max Atmosphere 100%Max Air (dirty) IP 65

4 *C min Atmosphere

5% Min Air (dirty)

IP 65

Indoor Location

55 *C max Atmosphere 95% Max Air IP 54^^

4 *C min. Atmosphere 5% Min Air IP 5^^

Air-conditioned Area

24 +/- 2 *C normal

Atmosphere 95% Max Air IP 42

50 *C Max. ^ Atmosphere 5 % Min Air IP 42

^ During Air Conditioning failure ^^ For non-ventilated enclosures. For Ventilated enclosures, protection class shall be IP 42.

1. For hazardous areas the protection class shall be in accordance with the requirements of the relevant NEC code for the location. 2. For PCs, OWS, EWS, Servers, Printers and other peripherals, maximum temperature limit shall be 35 *C. For LVS the same shall be 25 *C & for UPS the same shall be 40 *C


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12. SYSTEM CABINETS, PANELS & JUNCTION BOX

12.1 General Requirements

1. All control panels, system cabinets, local panels and local instrument enclosures, racks shall be furnished fully wired with necessary provision for convenience outlets, internal lighting, grounding, ventilation, space heating, anti-vibration pads and accessories as per IS:5039-1969 as required for completeness of the system.

2. All panels & cabinets shall be free standing type and have bottom entry for cables unless otherwise specified. The bottom of panels, cabinets, enclosures shall be sealed with bottom plate, compression cable glands and fire proof sealing material to prevent ingress of dust and propagation of fire. The Cabinets shall be designed for front & back access to components, terminals and wiring

3. The cabinets shall be provided with bottom glanding plate which shall be removable from inside and shall be provided with sufficient no. of knockouts. The details of knockouts shall be provided during detail engineering. All knockouts shall be provided with pluggable grommets.

4. The cabinets shall be of max. 2200mm height including base channel. The base channel shall be of 100 ISMC. All cabinets shall be of same height. Construction shall be modular. Contractor shall give the overall dimensions of each system and non-system cabinets in the format as per Schedule- 13 of this volume.

5. System & non-system cabinets shall have "look alike" appearance.

6. All electronic system cabinets shall be designed for 50 deg C operating under maximum ambient temperature without air conditioning system in service. Further cabinets, panels shall be so designed that temperature rise due to heat load does not exceed 10 deg. C above ambient temperature under all operating conditions. Necessary louvers, fans, limited packing density, adequate spacing between instruments, devices etc. shall be provided to maintain temperature rise within permissible limits.

7. Panels, cabinets enclosures wiring shall be arranged to enable the removal of modules/instruments and devices without unduly disturbing them.

8. All panels, cabinets, enclosures interiors shall be illuminated with rapid start fluorescent strip fixtures with door actuated switches. Door switch terminals shall be shrouded. All illuminated lights shall be provided with isolation switch in addition to door switch for maintenance & switching Off when not required. Illumination light shall be provided on both front & back sides if both sides are provided with equipments/instruments/terminal blocks requiring maintenance.


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9. Sufficient number of power receptacles with disconnect switches shall be installed within panels, enclosure and racks.

10. The local instrument enclosures/racks shall be provided locally for mounting of electronic transmitters and switches, etc.

11. All panels, cabinets shall be properly grounded. The grounding scheme shall be as approved by the owner.

12. Exterior steel surface shall be sand blasted, ground smooth, filed, primed, sanded and smooth enamel painted to give a good finish subject to minimum paint thickness of 65-75 microns for sheet thickness of 3 mm and 50 microns for sheet thickness of 2mm. Minimum 2 coats of primer and two sprays of final finish colour shall be applied to all surfaces.

13. The colour of the panel’s interior shall be brilliant white in the panel interior. External colour of the panels will be as RAL 7032 for LIE/ LIR and RAL 7035 for control room system cabinets.

14. All panels, enclosures, system cabinets, marshalling cabinets shall be provided with a minimum of 20% spare terminations and system cabinets shall be provided with spare space for 20% additional modules fully wired with connectors etc. in excess of the total requirement of the system design when the cabinets are delivered. The spare space capacity shall be distributed evenly throughout the cabinets.

12.2 System Cabinets

Table 12.1

Specifications for System Cabinets

S.N Features Minimum Requirements

1 Application For housing Signal conditioning cards, input/output cards, processor cards, power supply units etc.

2 Location Indoor

3 Type Free standing Vertical type

4 Protection class IP-42

5 Material & Thickness CRCA steel/3mm

6 Doors Double door with neoprene gasket, Lockable,

7 Cable entry Bottom with fire proof compound thickness 50 mm for sealing

8 Anti vibration pad Required, 15mm

9 Painting Interior- Brilliant White

Exterior- RAL 7035

10 Cabinet Dimension To be decided during detail engineering

11 Grounding M6 earthing stud shall be provided

12 Ventilation Fans & louvers with brass mesh


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required

13 Lighting rapid start fluorescent strip fixtures with door actuated switches required

14 Lifting arrangement Removable lifting eyebolts shall be provided

1. The racks in system cabinets shall have provision along with plug in sockets/back plane to house accommodate the spare slots/modules as specified elsewhere.

2. The system cabinets, racks in system cabinets, slots in the racks & the terminals shall have identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks, slots & details of the card type/service shall be inscribed on this metal tag.

3. Each cabinet shall be provided with one each 3 pin receptacles for 230 V, 1P, 50 Hz and receptacles for 24V DC.

4. One of the doors shall be provided with folder to keep the relevant engineering document of the cabinet.

5. All cabinets shall have common key for locks.

6. Door shall have concealed type of hinges with 120 degree swing.

7. Door latches shall be of the three-point type to ensure tight closing.

8. Separate Power & shield earthing bus shall be provided at the front & rear side of the cabinets. The earthing bus shall be isolated from panel body by suitable insulation material.

12.3 Marshalling Cabinets

Table 12.2

Specifications for Marshalling Cabinets


1 Application For termination of all cables originating from field.

2 Location Indoor

3 Type Free standing Vertical type

4 Protection class IP-44

5 Material & Thickness CRCA steel/ min. 2mm for panel sides & 3mm for gland plates

6 Doors Double door with neoprene gasket, Lockable,

7 Cable entry Bottom with fire proof compound thickness 50 mm for sealing

8 Terminal Blocks Rail mounted cage-clamp fused type


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with LED indication suitable for conductor size up to 2.5 mm2 & fused type with LED indication for power supply (24 VDC, 230 V AC, 110 V AC etc.) for instruments & equipments.

9 Anti vibration pad Required, 15mm

10 Painting Interior- Brilliant White

Exterior- RAL 7035

11 Cabinet Dimension To be decided during detail engineering


13 Ventilation Fans & louvers with brass mesh required

14 Lighting rapid start fluorescent strip fixtures with door actuated switches required

15 Lifting arrangement Removable lifting eyebolts shall be provided

1. Separate Marshalling cabinets for the system shall be supplied for terminating all cables originating from the field and for distributing the signals to different functional panels and cubicles.

2. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at one end to facilitate easy isolation shall be provided wherever necessary. All cabinets shall be provided with spare terminals for the spare inputs/outputs as specified else where in the specification. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied.

3. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Contractor, subject to approval by Owner / Consultant.

4. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers.

5. Each cabinet shall be provided with one each 3 pin receptacles for 230 V, 1P, 50 Hz and receptacles for 24V DC.

6. One of the doors shall be provided with folder to keep the relevant engineering document of the cabinet.

7. All cabinets shall have common key for locks.

8. Door shall have concealed type of hinges with 120 degree swing.

9. Door latches shall be of the three-point type to ensure tight closing.

10. Separate Power & shield earthing bus shall be provided at the front & rear side of the cabinets. The earthing bus shall be isolated from panel body by suitable insulation material

12.4 Local Instrument Enclosure & Racks


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1. Transmitters and switches, devices, etc. mounted in the field shall be suitably grouped together and mounted in local instruments enclosures in case of open areas of the plant and in local instrument racks in case of covered areas. These local instrument enclosures and racks shall be furnished as per the actual requirements finalised during detailed engineering stage. The exact grouping of instruments in a particular instrument enclosure/instrument rack shall be as finalised during detailed engineering stage subject to the owner's approval.

2. The local instrument enclosures shall be constructed of 2 mm sheet plate and shall be of modular construction with one or more modules and two end assemblies bolted together to form an enclosure. Vibration dampeners shall be installed for supporting each enclosure. The internal layout shall be such that the impulse piping/ blow down lines are accessible from back doors of the enclosure and the transmitters etc. are accessible from front side for easy maintenance. Gaskets shall be used between all mating sections to achieve protection class of IP-65.

3. The local instrument racks shall be free standing type constructed of suitable 3 mm thick channel frame of steel and shall be provided with a canopy to protect the equipment mounted in racks from falling objects, water etc. The canopy shall not be less than 3 mm thick steel, and extended beyond the ends of the rack. Bulk heads, especially designed to provide isolation from process line vibration shall be provided. Exact fabrication details shall be as finalized during detailed engineering stage. The junction box for racks also shall conform to IP 65 protection class.

4. Provision for continuous purging arrangement is to be made for all air and flue gas applications.

5. Each transmitter enclosure housing instruments i.e. for air and flue gas applications, requiring purge air for continuous air purging shall be provided with common purge air header, redundant air filter regulators of sufficient capacity, required pressure gauges, valves, fittings, SS tubing and individual purge meters for each purge line etc. as required.

6. As soon as the panel’s fabrication is over, Owner shall inspect the panels and further work on the panels, namely assembly, wiring and assembly of components shall be carried out only after the inspection.

7. The junction box of Local Instrument Enclosure & Racks shall be provided with hinged type door, latch for locking & gland plates for cable entry. All terminals in junction box shall be of rail mounted cage clamp type suitable for conductor size up to 2.5 Sq. mm.

12.5 Local Junction Box

Table 12.3


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Specifications for Junction Box


1 No. of Ways 32 (2X16) with 20% spares terminals

2 Material & Thickness 3 mm thick Stainless steel

3 Protection class IP-65 for outdoor/ IP 55 for Indoor

4 Cable entry Bottom

5 Mounting Suitable for Wall/column/structures mounting

6 Terminal Blocks Rail mounted cage-clamp type suitable for conductor size up to 2.5 mm2


8 Gland plate Removable type

9 Door

Single Lockable door with gasket, able to open sideways, turn able hinge based, latch type lock without handle with common key.

10 Accessories

Tag plate, clamps, fixtures, bolts (SS), nuts (SS), Gasket (Neoprene), cable glands (SS), Lugs (Brass), Fire proof compound for sealing.

1. All JB’s for outdoor application shall be provided with individual canopies to prevent ingress of water.

2. All JB’ shall have provision to add 10% additional TB’s.

3. The marking on terminal strips shall correspond to the terminal numbering on wiring diagrams.

4. Separate Terminal blocks shall be used for Analog & Digital Signals & also for signals with different voltage levels.

5. The terminal blocks shall be arranged with at least 100 mm clearance between two sets of terminal blocks and between terminal blocks and junction box walls.

6. Separate shield bus shall be provided with screw connection for terminating cable shields.

7. All spare cable entries shall be provided with plugs.

8. All wires in JB shall be neatly dressed & ferruled.

9. Double deck type terminal block shall not be used.

Table 12.4

Specifications for Cable Glands


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1 Type Double compression

2 Entry Thread ½“ NPT

3 Material Brass

4 Finish Cadmium Plated

5 Protection IP-54 or better

6 Accessories Neoprene gasket, Locknut, Reducer etc.


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10. PROCESS CONNECTION PIPING

The Contractor shall provide, install and test all required material for completeness of impulse piping system, sample piping system and air piping system as per the requirements of this clause on as required basis for the connection of instruments and control equipment to the process and make the system complete . However, the Contractor shall furnish during detailed engineering all relevant drawings, material and technical specifications of various items service wise for Owner's/Consultant’s approval.

Control and instrument piping & connections shall generally be designed in accordance with the following criteria and these criteria shall be closely co-ordinated with Mechanical Piping Contractor / Erector to fulfill the Mechanical Design Criteria also. This is a guideline for Piping design & selection. OEM standard proven practice in these regard are also acceptable if it is complying with applicable international standard & specifications as described in this section.

1. Pressure connections and piping up to the root valves for all pressure indicators, pressure switches, pressure transmitters, etc., shall be as indicated for miscellaneous piping.

2. Temperature indicators, temperature controllers, temperature switches, temperature detectors, and test well connections shall be as follows:

• Main steam -- 40 mm NPT.

• Extraction steam -- 40 mm NPT.

• Boiler feed water -- 32 mm NPT.

• Reheat steam -- 40 mm NPT.

• Duct temperatures -- 25 mm NPT.

• All others -- 19 mm NPT.

3. Flow transmitter connections and piping up to the root valves shall be 25 mm for all piping except orifice flanges, where 15 mm piping and valves shall be used.

4. Level switch connections and piping up to root valves shall be 25mm.

5. Level controllers and level transmitters of the displacement type shall have connections and piping up to root valves of 50 mm.

6. Level controllers and level transmitters of the differential pressure type shall have connections and piping up to root valves of 25 mm.

7. Instrument columns at tanks and pressure vessels shall generally be 65 mm minimum.


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A. Design Pressure and Temperature

Instrument primary piping design pressure and temperature shall be selected consistent with the requirements discussed in Mechanical Design Criteria of this specification, for the process pipe to which the instrument primary piping is connected. The following general criteria shall also apply:

Instrument primary piping for steam and other systems shall be designed for 1-½ times the maximum sustained process pressure and temperature (plus 20°C).

B. Sizes of Instrument Primary Piping

Instrument primary piping shall not be smaller than the connection at the process pipe root valve and/or the following (metric sizes are nominal):-

1. 20 mm for pressure measurement piping with a design pressure equal to or less than 42.0 bar and a design temperature equal to or less than 400°C.

2. 25 mm for pressure measurement piping with a design pressure greater than 42.0 bars or a design temperature greater than 400°C.

3. Flow and level measurement by differential pressure shall also use primary piping conforming to the above requirements; however, flange tap connections may be of 13 mm size.

4. Float actuated level switch devices shall be supported on connecting piping not smaller than 25 mm.

5. Level controllers and transmitters of the displacement float type shall be supported on connecting piping not smaller than 50 mm.

6. Instrument columns for float actuated level switches and displace-ment float devices shall be piping of not less than 65 mm.

7. Primary piping internal diameter shall not be less than 8 mm between the process connection and instrument blow down valve.

C. Materials for Instrument Primary Piping

Material for instrument primary piping connecting to the root valve shall preferably be the same as that used in the process system to which it is connected. Higher strength materials may be substituted in the interest of standardization; however, welding procedures at the point of joining the instrument primary piping to the process piping must be appropriate to the combination of materials involved. Copper may be used only for compressed air services that use copper process piping.


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D. Insulation of Instrument Primary Piping

Instrument primary piping connecting to high temperature systems, which might become hot enough to injure personnel during blow down of the instrument line, shall be insulated where such hazard exists. Insulation materials, exterior finish, and metal lagging shall conform to the standards adopted for the process piping.

All materials supplied shall be suitable for intended service, process, operating conditions and type of instruments used and shall fully conform to the requirements of this specification. The material offered by the Contractor shall be from reputed, proven manufacturer.

E. Process Connection Size

Size of tapping point, Stub No. and size of Root valves for different type

of measurements.

These shall be as follows:

Table 10.1

Process Connection Stub & Root valve

S. N.

Quantity

of root

valves

(Nos.)

Size of stub and root

valves Service condition

A. Pressure and Differential pressure measurement

1 2 25NB >=62 bar or 425degree C

2 1 15NB <62 bar and 425 degree C

B. Level Gauge and Switch

1 2 25 NB >= 62 bar or 425 degree C


C. Level Transmitter (Displacement Type)



D. Stand pipe for Level measuring instrument

1 2 80 NB >=62 bar or 425degree C

2 1 80 NB <62 bar and 425 degree C

E. Flow measurement


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S. N.

Quantity

of root

valves

(Nos.)

Size of stub and root

valves Service condition


F. Level measurement


G. Sampling system measurement (system and water service)

1 2 25 NB >=62 bar or 425degree C

2 1 25 NB <62 bar and 425 degree C

10.1 Impulse Piping, Tubing, Fittings, Valves & Valve Manifolds

All impulse pipes shall be of seamless type conforming to ANSI B36.10 for schedule numbers, sizes and dimensions etc. The material of the impulse pipe shall be same as that of main process pipe. For various applications specification of impulse pipe materials and associated fittings and valves shall be as given in Table –10.2 (Process Connection Piping).

Table 10.2

Process Connection piping

S. N Service

Size Impulse

tube

material

Impulse

Pipe

material

Impulse line

fitting

material

valves

material

Pipe Tube ANSI rating ANSI

Rating

1

Main steam / Saturated steam

SCH.XXS 21.34mm OD

1.7 mm ODX 1.65HK

SS 316

ASTM-A-335-Gr-P-22 (alloy steel)

ASTM-A-182-Gr-F-22

ASTM-A-182-Gr-F-22

9000 LBS 2500 SPL. Class

2

Hot reheat / extraction to HPH

SCH.80 21.34mm OD

12.7 mm ODX 1.65mm THK

SS 316

ASTM-A-335-Gr-P-22 (alloy steel)

ASTM-A-182-Gr-F-22

ASTM-A-182-Gr-F-22

9000 LBS 2500 SPL. Class


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S. N Service

Size Impulse

tube

material

Impulse

Pipe

material

Impulse line

fitting

material

valves

material


Rating

3

Cold reheat / extraction / heater drains / condensate system; aux. steam

SCH.80 21.34mm OD


SS 316

ASTM-A-106-Gr-B (carbon steel)

ASTM-A-105-Gr-II

ASTM-A-105-Gr-II

3000LBS 400LBS

4 Water system

SCH.80 21.34mm OD


SS316


ASTM-A-105-Gr-II

ASTM-A-105-Gr-II

3000LBS 400LBS

5. Instrument air system

SCH.40 21.34mm OD(pipe through out)


SS316

IS 1239 Heavy Class (Galvanisied)

ASTM-A-105-Gr-II

ASTM-A-105-Gr-II

3000LBS 150LBS

6. Service air system

SCH.40 21.34mm OD


SS 316

IS 1239 Heavy Class (Black)

ASTM-A-105-Gr-II

ASTM-A-105-Gr-II

3000LBS 150LBS

7. Vacuum

SCH.40 21.34mm OD

7 mm ODX1.65mm THK

SS 316


ASTM-A-105-Gr-II

ASTM-A-105-Gr-II

3000LBS 150LBS


Page 450 of 495





S. N Service

Size Impulse

tube

material

Impulse

Pipe

material

Impulse line

fitting

material

valves

material


Rating

8. Make up water system

SCH.40 21.34mm OD

12.7 mm ODX1.65 mm THK

SS 316

ASTM-A-312-TP-316 (SS)

ASTM-A-182-Gr-IF6a

ASTM-A-182-Gr-IF6a

3000LBS 150LBS

Notes:-

1. Impulse pipe thickness will be selected as per ANSI B 36.10. based on the schedule indicated against each service.

2. Wherever impulse tubes are provided, all the fittings required for these shall be SS316.

The following guidelines shall also be considered along with the Table 10.1 &

10.2 for size, material and rating for impulse line/tube fittings and accessories:

a. Impulse line / tube fittings and accessories

1. Nipple shall be provided for root valve size more then ½ inch and the nipple size shall be same as the root valve size. Reducer / adepter shall be provided to suit instrument connection, where nipple, root valve size is more then ½ inch.

2. Bulk head fitting socket welded type to be provided at instrument rack / enclosure.

b. Fittings

1. All fittings except the last fitting connecting to the instrument shall be socket welded. The size of the fittings shall be same as the impulse line size.

2. The fitting connecting to the instrument shall have a size and thread to suit the instrument connection.

c. Drain

Drain shall be provided for all water / steam and non-inflammable / non-corrosive fluids only.


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d. Drain Valve

1. Two numbers of globe drain valves shall be provided for process conditions of 425 degree C or 62 bar and higher.

2. One number globe drain valve shall be provided for process conditions of less than 425 degree C and 52 bar.

3. The valve size shall be same as impulse piping / tubing size.

e. Funnel with drain header

1. This shall be provided in the racks for blowing / draining out the process fluid in the impulse tubings.

2. The size of drain header shall be 1”

3. When instruments are mounted local to the tapping point and are not mounted in rack, or panel or enclosure. The drains shall be connected to the nearest floor level or plant drain.

f. Instrument Valves

1. Type of the valve shall be needle valve with built in drain valve.

2. Sizing of the valve shall be ½”.

g. Right / left threaded fittings

1. This shall be provided for installation / removal of instruments without disturbing the tubing / piping.

h. A suitable adapter shall be provided to install the instruments on ½” right-left threaded fittings.

i. A ½” vent line with a ½” isolation valve shall be provided in the instrument rack for air and compressible fluids or other wise if the installation call for eg., for liquid service where the transmitter is located at a higher elevation than the tapping point.

j. For air / flue gas measurement a drain pot with plug shall be provided in place of drain valves.


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Stainless steel tube shall be provided inside enclosures and racks from tee connection to valve manifold and then to instrument. For high pressure/temperature applications (piping class A,B,C & D of the Table 10.1)the material shall be ASTM A 213 TP 316H and for other applications material shall be ASTM A 213 TP 316L. The wall thickness of the tube shall be in accordance with the ANSI B31.1 standard.

All fittings shall be forged steel and shall conform to ANSI B16.11. The material of forged tube fittings for shaped application (e.g. tee, elbow etc.) shall be ASTM A182 Gr. 316 H for high pressure/ temperature applications (as defined above) and ASTM A182 Gr. 316L for other applications. The material for bar stock tube fitting (for straight application) shall be 316 SS. Metal thickness in the fittings shall be adequate to provide actual bursting strength equal to or greater than those of the impulse pipe or SS tube, with which they are to be used.

The source shut-off (primary process root valve) and blow down valve shall be as per Table 10.1. The disc and seat ring materials of carbon steel and alloy steel valves shall be ASTM A-105 and ASTM A-182, Gr. F22, hard faced with stellite (minimum hardness - 350 BHN.) The surface finish of 16 RMS or greater is required in the area of stem packing. The valve design shall be such that the seats can be re-conditioned and stem and disc may be replaced without removing the valve body from the line.

The valve manifolds shall be of 316 SS with pressure rating suitable for intended application. 2 valve manifold and 3 valve manifold shall be used for pressure measurements using pressure transmitters/ pressure switches and differential pressure transmitters/ switches respectively. 5 valve manifold shall be used for remaining applications like DP, flow and level measurements.

For Pressure/D.P gauges in fluid application two-way globe valve on each impulse line to the instrument and in air/flue gas application two way gate valve on each impulse line to the instrument shall be provided near the instrument. These shall be in addition to the three way gauge cock provided along with the pressure/D.P gauges.

Table 10.3

Specification for Seamless SS Pipe

S.N Property Requirement

1 Reference ASTM A-312 TP-316

2 Material Grade TP-316

3 Type Seamless/Plain end

4 Size ½” NB

5 Schedule 40/60/80

6 Standard Length 5 metre


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Table 10.4

Specification for Seamless SS Pipe Fittings


1 Reference ASTM A-182 F-316

2 End Connection Socket welded

3 Type Forged conforming to ANSI B16.11

4 Size ½” NB

5 Rating 3000/6000/9000 lbs

6 Type of Fittings Reducing coupling, Male-Female reducer, Straight coupling, Equal Tee, Three Piece Union, Elbow, Cap etc.

Table 10.5A

Specification for Seamless SS Tube (1/2”)




3 Type Cold Drawn annealed, pickled, passivated, descaled, hydraulically cleaned seamless tube.

4 Size ½” OD X 2.1 mm thick

5 Properties

Tube shall be free from scratches & suitable for bending & capable of being flared by hardened & tapered steel pin. The expanded tube shall show no crack or rupture. Hardness shall be RB 80

6 Test Pressure 400 Kg/Sq mm minimum

7 Tolerance +/- 0.13 mm for outside dia. +/- 15% for wall thickness

8 Test Flare, Hardness, Ball & Bubble test


Table 10.5B

Specification for Seamless SS Tube (1/4”)




3 Type Cold Drawn annealed, pickled, passivated, descaled, hydraulically cleaned seamless tube.

4 Size 1/4” OD X 1.2 mm thick


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5 Properties

Tube shall be free from scratches & suitable for bending & capable of being flared by hardened & tapered steel pin. The expanded tube shall show no crack or rupture. Hardness shall be RB 80

6 Test Pressure 400 Kg/Sq mm minimum

7 Tolerance +/- 0.13 mm for outside dia. +/- 15% for wall thickness

8 Test Flare, Hardness, Ball & Bubble test


Table 10.6

Specification for Seamless SS Tube Fittings


1 Reference ASTM A-182

2 Material Grade SS 316 forged

3 Type Double ferrule double compression

4 Ferrule SS 316

5 Size To suit SS tubing & NPT end connection

6 Type of fittings

Male/Female connectors, elbow, Equal & Unequal Tee, Cross, Straight connector, bulk head unions, etc. as required to suit the installation.

Table 10.7

Specification for Instrument Valve Manifolds


1 Type Two valve manifold/Three Valve Manifold Five valve manifold

2 Mounting Remote 2” pipe mounting

3 Construction Single Block (Bar Stock)

4 Material Forged body & bonnet AISI 316 SS

5 Ports ½” NPT

6 Rating 420 Kg/ cm2 at ambient

7 Packing PTFE Wafer

8 Seat & Stem AISI 316 SS

9 Plug AISI 316 SS free to turn on stem/ 17-4 PH

10 Handle AISI 316 SS

11 Connection Straight

12 Accessories Plug for all ports Mounting Bracket, nut, bolts etc.


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10.2 Air Supply Piping

1. All pneumatic piping, fittings, valves, air filter cum regulator and other accessories required for instrument air for the various pneumatic devices/ instruments shall be provided.

This will include as a minimum air supply to pneumatically operated control valves, actuators, instruments, continuous and intermittent purging requirements of Local Instrument Enclosures (LIE) etc.

2. For individual supply line and control signal line to control valve, 1/4 inch size light drawn tempered copper tubing conforming to ASTM B75 shall be used. The thickness of copper tubing shall not be less than 0.065 inch and shall be PVC coated. The fittings to be used with copper tubes shall be of cast brass, screwed type.

3. All other air supply lines of 1/2 inch to 2 inch shall be of carbon steel hot dipped galvanized inside and outside as per IS-1239, heavy duty with threaded ends. The threads shall be as per ASA B.2.1. Fittings material shall be of forged carbon steel A234 Gr. WPB galvanized inside and outside, screwed as per ASA B2.1. Dimensions of fittings shall be as per ASA B16.11 of rating 3000 lbs.

4. Instrument air filter cum regulator set with mounting accessories shall be provided for each pneumatic device requiring air supply. The filter regulators shall be suitable for 10 kg/ sq.cm max. inlet pressure. The filter shall be of size 5 microns and of material sintered bronze. The air set shall have 2 inch size pressure gauge and built in filter housing blow down valve. The end connection shall be as per the requirement to be finalised during detailed engineering.

5. All the isolation valves in the air supply line shall be gate valves as per ASTM B62 inside screw rising stem, screwed female ends as per ASA B2.1. Valve bonnet shall be union type & trim material shall be stainless steel, body rating 150 pounds ASA. The valve sizes shall be 1/2 inch to 2 inch.

Table 10.8

Specification for Instrument Air Header


For Panel For Field

1 Material SS 316 SS 316

2 Inter Connection 2” NPT (M) 1” NPT (M)

3 Header Take-Off SS 316 SS 316

4 Take-Off Connection ½” NPT (M) ½” NPT (M)

5 Take-Off Valve ½” Ball Valve SS 316 ½” Ball Valve SS 316

6 Drain ½” Ball Valve SS 316 at the lowest point

½” Ball Valve SS 316 at the lowest point


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Table 10.9

Specification for CS Pipe


1 Reference ASTM A-106 Gr. C

2 Material Cold Drawn Seamless CS

3 Type Seamless/ threaded ends as per ASA B2.1/ Hot dip Galvanised from Inside & outside as per IS-1239

4 Size ½” to 2” NB

5 Schedule 80/160


Table 10.10

Specification for CS Pipe Fittings


1 Reference ASTM A-234/ ASA B16.11

2 Type Forged/ hot dip galvanised from inside & outside

3 Size ½” to 2” (as required)

4 Rating 3000/6000/9000 lbs.

5 End Connection Threaded as per ASA B2.1

6 Type of Fittings Reducing Coupling, Male-Female reducer/ Straight Coupling/ Equal Tee/ Three piece Union/ Elbow/ Cap etc.

Table 10.11

Specification for CS Globe Valve


1 Reference ASTM A-105/ASTM B62

2 Type Globe

3 Construction Forged body cadmium plated

4 Rating PN 40/PN 160/ PN 320/ PN 400

5 End Connection Screwed Female ends as per ASA B2.1

6 Material

Body- Carbon steel Stem- Hardened Steel Plug- AISI 316 SS Seat- SS Stellited

7 Size ½” to 2 “ as required

8 Packing Teflon/Grafoil as required

9 Hand wheel CS

10 Yoke ASTM A105

11 Design Standard As per ANSI B16.34


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interferences and power line borne surges especially encountered in power plant environment. Contractor’s equipment, which is vulnerable to electrical noise interference or surge, shall be suitably immunized to eliminate possible problems.

Contractor shall be fully responsible for detailed implementation of the type, size, shielding, input balancing, ripple amplitude and grounding for field inputs and for equipment furnished by Contractor to achieve an installation with minimum noise coupling from all sources.

Any additional equipment, services required for effectively eliminating the noise problems shall be identified and included.

5.10 Surge Protection for Microprocessor based Equipments

All microprocessor-based system / equipment shall be able to withstand the noise and surges inherent in a powerhouse. The system / equipment shall be designed to successfully withstand without damage to components and / or wiring, application of surge withstand capability (SWC) wave whose shape and characteristics are defined in ANSI publication C37.90a, 1974 entitled “Guide for Surge Withstand Capability (SWC) Tests”.

Details shall be provided of production tests being carried out to fully satisfy Owner/Consultant that the proposed system / equipment meets the above requirement and to assure that the products furnished shall be of the desired grade. To immunize the system against surge or coupling it is preferred that freewheeling diodes, surge suppressors, opto / galvanic isolators be used as required.

5.11 Drive Control Philosophy

The Drive control & measurement philosophy for the project is detailed in this section.

5.11.1 Bi-directional drives (inching or open/close)

1. All bi-directional drives shall be operable from Remote i.e. from CCR.

2. Remote manual operation of all drives shall be carried out from OWS.

3. Remote Open/Close commands, generated in control system shall be issued to MCC module through interposing relays located in respective MCC module in the MCC room. Latching of commands shall be provided in control system logic which shall be reset by Limit/Torque switch feedback. The Limit/Torque switch feedback from drive shall be directly wired to Control System.


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4. Necessary Electrical protections shall be realized at MCC module whereas process interlocks & protections shall be realized in Control system.

5. Following signal exchange shall be envisaged between Drive & Control system:

• Open Limit Switch (Both NO & NC contacts)

• Close Limit Switch (Both NO & NC contacts)

• Open Torque Actuation

• Close Torque Actuation

• Position feedback (4-20 mA, two wire electronic type) for inching drive

6. Following signal exchange shall be envisaged between MCC & Control system(Remote I/O cabinet of control system located in/near MCC room):

• Switchgear available

• Switchgear disturbance

• Open Command

• Close Command

The block diagram of the bidirectional drive (On-Off type & Inching type) controls is shown in drawing no. LII-GEOE11019-G-00172-327 & LII-GEOE11019-G-00172-328.

5.11.2 Unidirectional LT drives

1. Unidirectional LT drives shall be operable only from Remote i.e. from CCR. In addition, Local pushbutton shall be provided only for emergency stopping of drive. Local start operation of the drive is not envisaged.


3. Remote Start/Stop commands shall be generated in Control system & shall be issued to MCC module through interposing relays located in respective MCC modules.

4. Emergency stop of the drive shall be envisaged from the local pushbutton provided near the drive. The stop push button (Stay put


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type) shall be provided with a press to lock & turn to release type keyless mechanism. Under locked position the drive operation is inhibited from remote. The local emergency stop push button shall be wired directly to MCC.


6. Current transducer with 4-20 mA type outputs shall be provided in the MCC for monitoring the current in Control System for all Drives greater than 90 KW. Auxiliary power supply to these transducers shall be from the control supply of the respective MCC modules.

7. Following signal exchange shall be envisaged between MCC & Control system(Remote I/O cabinet of control system located in MCC room):



• On Feedback

• Off Feedback

• Start Command

• Stop Command

8. All Numerical relays/Intelligent controllers for LT drives shall be interfaced to Control System through IEC 61850 protocol.

The block diagram of the Unidirectional LT drive controls is shown in drawing no. LII-GEOE11019-G-00172-329.

5.11.3 Solenoid Operated drives

1. Solenoid operated drives shall be operable only from Remote i.e. from CCR.


3. Remote Open/Close commands shall be generated in Control system & shall be issued to the Solenoid through interposing relays, located in Relay Panel.

4. Necessary process interlocks shall be realized in Control system.

5. Following signal exchange shall be envisaged between solenoid drive & Control system:

• Open Limit Position

• Close Limit Position

• Open Command

• Close Command


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The block diagram of the Solenoid drive controls is shown in drawing no. LII-GEOE11019-G-00172-331

5.11.4 HT drives

1. HT drives shall be operable only from Remote i.e. from CCR. In addition, Local pushbutton shall be provided only for emergency stopping of drive. Local start operation of the drive is not envisaged.


3. Remote Start/Stop commands shall be generated in Control system & shall be issued to MCC module through interposing relays located in respective MCC modules.

4. Emergency stop of the drive shall be envisaged from the local pushbutton provided near the drive. The stop push button (Stay put type) shall be provided with a press to lock & turn to release type keyless mechanism. Under locked position the drive operation is inhibited from remote. The local emergency stop push button shall be wired directly to MCC.


6. Current transducer with 4-20 mA type outputs shall be provided in the MCC for monitoring the current in Control System for all Drives. Auxiliary power supply to these transducers shall be from the control supply of the respective MCC modules

7. Following signal exchange shall be envisaged between MCC & Control system(Remote I/O cabinet of control system located in MCC room):



• Master Trip relay Operated

• On Feedback

• Off Feedback

• Trip Feedback

• Emergency stop feedback

• Start Command

• Stop Command

• Current Feedback


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8. All Numerical relays/Intelligent Controllers for HT drives shall be interfaced to Control System through IEC 61850 protocol.

The block diagram of the HT drive controls is shown in drawing no. LII-GEOE11019-G-00172-330

5.11.5 Variable Frequency Drive (VFD) [If Applicable]

1. VFD shall be operable from Remote i.e. from CCR & from VFD Local Display unit. In addition, Local pushbutton shall be provided only for emergency stopping of drive.

2. Remote manual operation of VFD shall be carried out from OWS.

3. Remote Start/Stop commands shall be generated in Control system & shall be issued to VFD Panel through interposing relays located in VFD Panel.

4. Emergency stop of the drive shall be envisaged from the local pushbutton provided in the field. The stop push button (Stay put type) shall be provided with a press to lock & turn to release type keyless mechanism. Under locked position the drive operation is inhibited from remote. The local emergency stop push button shall be wired directly to VFD panel.

5. Necessary Electrical protections shall be realized at VFD module whereas process interlocks & protections shall be realized in Control system.

6. Following signal exchange shall be envisaged between VFD & Control system:



• On Feedback

• Off Feedback

• Trip Feedback

• Emergency stop feedback

• Start Command

• Stop Command

• Current Feedback

• Speed feedback

• Speed Setpoint


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7. The VFD shall also be interfaced with control system via Modbus soft link.

The block diagram of the Variable Frequency drive controls is shown in drawing no. LII-GEOE11019-G-00172-133


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11.2.4 Routine Test

To be carried out by Contractor during various stages of manufacture. Owner / Consultant shall review the related documentation.

1. Insulation & jackets: All tests as per IS – 5831 except insulation resistance, voltage & spark test shall be as per BS – 5308, Part II (1986)

2. Armor test as per IS – 3975

3. Conductor resistance

4. Cable capacitance and L/R ratio.

11.2.5 Acceptance Test

These tests shall be carried out in the presence of Owner / Consultant

1. Continuity test

2. Voltage test as per BS – 5308 Part II (1986)

3. Conductor resistance and drain wire resistance

4. Cable capacitance and L/R ratio test.

5. Tests for uniformity of galvanization of armor as per IS – 2633

6. Oxygen and temperature index test as per ASTM D – 2863

7. Dimensional checks for overall diameter and under armour / over armour diameter.

8. Overall finish check. In case of any lump, Owner / Consultant will have the right to cut outer sheath for lump portion and reject the cable.

9. Checking of drum length & overall length tolerances.

Immediately after completion of electrical tests, the ends of the cable shall

be sealed to prevent ingress of moisture with suitable PVC / Rubber caps

11.3 Specifications of Optical Fibre Cables (OFC)

1. This specification describes the minimum general requirements for the design, manufacture, supply, inspection, installation, testing & commissioning of optical fibre cable & accessories.

2. Contractor shall consider all related activities such as cable stripping, Cable entry in boxes & panels, cable fibre splicing/fusion, cable performance testing & other services, to achieve properly documented & operational cable network.

3. OFC shall be installed on cable tray, duct bank, cable trench installation as necessary. For outdoor applications the cable shall be armoured with Poly Ethylene sheathing. In all cases cable shall be routed through


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suitable grade HDPE permanently lubricated protection pipe as per IS-4984, IS-12235 & TEC.G/CDS-08/01 of suitable size @ 53% fill factor.

4. The optical fibre core shall be of ultrapure fused silica glass coated with UV cured acrylate suitable to withstand temperature of about 80 deg. Centigrade continuously.

5. OFC shall be 4 / 8 / 12 core, galvanized corrugated steel taped armored, fully water blocked with dielectric central member for outdoor / indoor application so as to prevent any physical damage. The cable shall have multiple single-mode or multi-mode fibres on as required basis so as to avoid the usage of any repeaters. The core and cladding diameter shall be 9 +/- 1 micrometer and 125 +/- 1 micrometer respectively. The outer sheath shall have Flame Retardant, UV resistant properties & to be identified with the manufacturer’s name, year of manufacture, progressive automatic sequential on-line marking of length in meters at every meter on outer sheath.

6. The cable core shall have suitable characteristics and strengthening for prevention of damage during pulling viz. steel central member, Loose buffer tube design, 4 fibres per buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly or better material. The cable shall be suitable for maximum tensile force of 2000 N during installation, and once installed, a tensile 1000 N minimum. The compressive strength of cable shall be 3000N minimum & crush resistance 4000 N minimum. The operating temperature shall be -20 Deg.C to 70 Deg.C.

7. The splicing loss of any two fibres in any case shall not exceed 0.10 db/splice.

8. The Contractor shall submit the ageing characteristics of the offered optic fibres. The total additional attenuation above the nominal attenuation due to regular splices, repair splices, connectors, temperature variation, ageing etc. shall be indicated by the Contractor.

9. Fibre coloring shall conform to EIA/TIA-598. The color-coding shall be permanent thus withstanding normal handling; e.g., during termination, testing, or cable relocation. Refer to EIA – 359 for color identification and coding.

10. Cables shall be designed & tested in accordance with ISO 11801, TIA-568 & ICEA 596 and Performance specifications shall be measured in accordance with the Fibre Optic test procedures(EIA/TIA -455 documents) test procedures of IEC-60793 & IEC-60794.

11. The OFC shall generally conform to the following specifications


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Table 11.4A

Specifications for Single Mode Optical Fibre

S.N Feature Minimum Requirement

1 Maximum Uncabled Attenuation Coefficient

@1310 nm 0.4 dB/km

@1550 nm 0.3 dB/km

2 Mode field Diameter @1310 nm 9.2±0.4 µm

@1550 nm 10.4±0.8 µm

3 Maximum Cable Cut-off Wavelength 1260 nm

4 Maximum Zero Dispersion Wavelength 1321.5 nm

5 Minimum Zero Dispersion Wavelength 1301.5 nm

6 Maximum Zero Dispersion Slope 0.092 ps/nm2·km

7 Maximum Polarization Mode Dispersion 0.2 ps/√km

8 Gigabit Ethernet Length 1000BASE-LX 2-5000 mtrs.

9

Ten Gigabit Ethernet Length

10GBASE-LX 2-10000 mtrs.

10GBASE-LX4 2-10000 mtrs.

10 Maximum Core/cladding Concentricity Error 0.5 µm

11 Cladding Diameter 125.0 ± 1.0 µm

12 Cladding Non-circularity 1 %

13 Coating Diameter 245 ± 5 µm

14 Maximum Coating Concentricity Error 12.5 µm

15 Temperature Dependence (-60 to +85C) 0.05 dB/km

16 Temperature & Humidity Cycling (-10 to + 85C, 4 to 90% RH)

0.05 dB/km

17 Minimum Proof Test 100 kpsi

18 Bending Induced Attenuation (100 turns, 75mm diameter)

0.5 dB

Table 11.4B

Specifications for Multi Mode Optical Fibre


1 Maximum Uncabled Attenuation Coefficient

@850 nm 3 dB/km

@1300 nm 0.7 dB/km

2 Overfilled Launch Bandwidth

@850 nm 200 MHz·km

@1300 nm 500 MHz·km

3 Gigabit Ethernet Length 1000BASE-SX 2-300 mtrs.


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1000BASE-LX 2-550 mtrs.

4

Ten Gigabit Ethernet Length

10GBASE-SR 2-33 mtrs.

10GBASE-LX4 2-300 mtrs.

5 Numerical Aperture 0.275 ± 0.015

6 Core Diameter 62.5 ± 3.0 µm

7 Maximum Core Non-circularity 6 %

8 Maximum Core/cladding Concentricity Error 3 µm

9 Cladding Diameter 125.0 ± 2.0 µm

10 Cladding Non-circularity 2 %

11 Coating Diameter 245 ± 10 µm

12 Maximum Coating Concentricity Error 12.5 µm

13 Temperature Dependence (-60 to +85C) 0.2 dB/km

14 Temperature & Humidity Cycling (-10 to + 85C, 4 to 90% RH)

0.2 dB/km

15 Minimum Proof Test 100 kpsi

16 Bending Induced Attenuation (100 turns, 75mm diameter)

0.5 dB

12. The cables shall be supplied in non-returnable strong wooden (or

alternatively steel) drums provided with lagging of adequate strength, constructed to protect the cable against any damage and displacement during transit, storage and subsequent handling and stringing operations in the field.

13. Test on Fibre optic cable:

Table 11.4C

Type Test Requirement for Fibre Optic Cables

S.N Test Requirement Standard

A Optical Characteristics of Fibres

1 Attenuation

IEEE Std. 1138 IEEE STD. P1222 (EIA/TIA – 455-61,78A) (IEC 793-1-C1A,B,C)

2 Cut off wavelength

IEEE STD. 1138 IEEE STD PI222 (EIA-455-80, 170) (IEC-793-1-C7A,B)

3 Fibre Dispersion IEEE STD. 1138 IEEE STD. P1222


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S.N Test Requirement Standard

(EIA/TIA-455-168A,169A,175A) (IEC-793-1-C5A,B,C)

4 Frequency Response IEC-793-1-C2B

5 Mode Field Diameter

IEEE STD. 1138 IEEE STD. P1222 (EIA/TIA-455-164A,165A,167A) (EIA-455-174) (IEC 793-1-C9A,B,C,D)

6 Temperature Cycling

IEEE STD. 1138 IEEE STD. P1222 (EIA/TIA-455-69A) (IEC 793-1-D1)

B Mechanical Characteristics of Fibres

1 Abrasion IEC 793-1-B4

2 Core Concentricity IEC 793-1-A3

3 Macro Bending EIA/TIA-455-62A (IEC 793-1-C11)

4 Micro Bending IEC-793-1-C3

C Proof Test IEC-793-1-B1

D Strippability IEC 793-1-B6

E Visual Examination EIA/TIA-455-13 (IEC 793-1-B5)

11.4 Instrumentation Cable Interconnection & Termination Philosophy

The cable interconnection philosophy to be adopted shall be such that expensive grouping of signals by large scale use of field mounted Group Junction Boxes (JBs) at strategic locations. (where large concentrations of signals are available, e.g. valves limit and torque switches, switchgear) is done and consequently cable with higher number of pairs are extensively used. The details of termination to be followed are mentioned in the following Table:

Table 11.5

Instrumentation Cable Interconnection & Termination Philosophy

S.N Application Type of Termination Type of

Cables From (A) To (B) End A End B

1.

Limit, Torque switches of valves / dampers / drives (integral junction box)

Marshalling cubicle / Marshalling cum Termination Cubicle / Local group

Plug-in connector

Posts mount cage clamp type

G


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S.N Application Type of Termination Type of

Cables From (A) To (B) End A End B

JB

2.

Transmitters, E/P converters, process actuated switches mounted in LIE / LIR

Integral junction box of LIE / LIR

Plug-in connector

Cage clamp (rail mount)

F, G

3. RTD heads Local junction Box

Plug-in connector

Cage clamp (Rail mount) type

F

4. Thermocouples Junction Box Plug in connector


A, B, C*

5. Other Field Mounted Instrument

Local JB / Group JB

Plug in connector

Screwed, Cage clamp (Rail mount) type

F (For analog signals) G (For Binary Signals)

6.

Junction Box (For Thermocouples for interlock and protection

Marshalling Cubicle / Marshalling cum Termination Cabinet


Screwed, Cage clamp (Rail mount) type

A, C*. These signals shall preferably through 6 pair cable

7.

Local junction box, Instrument Junction box of LIE / LIR / Group JB / MCC / SWGR

Group JB



F, G

8.

Local junction box, Instrument Junction box of LIE / LIR / Group JB / MCC / SWGR

Marshalling Cubical / Marshalling cum termination Cabinet


Posts mount cage clamp type

F, G

9.

Marshalling Cubical / Termination Cabinet

Electronic system cabinet

Cage clamp post mounted type

Plug-in connector / Other System as per manufacturer’s Standard

Internal Wiring


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Notes:

1. Normally 10% spare cores shall be provided when the numbers of pairs of cables are more than four pairs.

2. For analog signals, individual pair shielding & overall shielding & for binary signals only overall shielding of instrumentation cables shall be provided.

3. * For high temperature applications only.

4. Instrument Cabling for instruments / equipment of specialized / proprietary Control System shall be as per manufacturer’s standard.

11.4.1 Terminal Blocks

1. All terminal blocks shall be rail mounted/post mounted cage clamp type with high quality non-flammable insulating material of melamine suitable for working temperature of 105 deg. C. The terminal blocks in field mounted junction boxes, temperature transmitters, instrument enclosures/racks, etc. shall be suitable for cage clamp connections. The terminal blocks in Control Equipment Room logic / termination / marshalling cubicles shall be suitable for the post mounted cage clamp connection at the field input end. The terminal blocks for TG integral control system Input/Output connections from/to SWGR/MCC, shall be provided with built in test and disconnect facilities complete with plug, slide clamp, test socket etc. The exact type of terminal blocks to be provided by the Contractor and the technical details of the same including width etc shall be subject to Owner’s / Consultant’s approval.

2. All the terminal blocks shall be provided complete with all required accessories including assembly rail, locking pin and section, end brackets, partitions, small partitions, test plug bolts and test plug ( as specified above for SWGR connections), transparent covers, support brackets, distance sleeves, warning label, marking , etc.

3. The marking on terminal strips shall correspond to the terminal numbering on wiring diagrams. At least 20% spare unused terminals shall be provided everywhere including local junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All terminal blocks shall be numbered for identification and grouped according to the function. Engraved labels shall be provided on the terminal blocks.

4. The terminal blocks shall be arranged with at least 100 mm clearance between two sets of terminal blocks and between terminal blocks and junction box walls.

5. For ensuring proper connections, Contractor shall provide suitable accessories along with insulation sleeves. The exact connecting accessory shall be finalized as per application during detail engineering stage subject to Owner’s / Consultant’s approval without any cost repercussions.


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LAHMEYER INTERNATIONAL (INDIA) PVT. LTD.

CONSULTING ENGINEERS, GURGAON, INDIA

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2 X 500 MW NEYVELI NEW THERMAL

NEYVELI LIGNITE CORPORATION LTD, NEYVELI, TAMILNADU

POWER STATION


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LAHMEYER INTERNATIONAL (INDIA) PVT. LTD.

CONSULTING ENGINEERS, GURGAON, INDIA

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INSTRUMENT INSTALLATION DIAGRAM

2 X 500 MW NEYVELI NEW THERMAL

NEYVELI LIGNITE CORPORATION LTD, NEYVELI, TAMILNADU

POWER STATION


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ent of order.

g spares (if aers reply to uring commis

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COMPL

e with followin

al details, coare no exclus

submitted inerein.

Customer amarked in throm review ospection (Lloe equipment

c. to be subs, as submittal during cont

with respect t

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s (if any) for ase price.

ISED REPRESEN

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PEI: NOIDA, SE


W NEYVELI TP

IANCE CER

ng by signing

onstruction fesions/ deviat

n the event

pproval in the QP at th

of various tesoyds, TUV ot by the bidde

bmitted durinted with offetract stage.

to specificati

ivalent or sue suitable f

plied on ‘As Rcommissionime shall be s

USTOMER a

ll be in bidde

hall stand vaL/Customer.

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NTATIVE DATE

ECTOR 16A, UP


PP

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EC NO: PE-TS-4

LUME: III

CTION:

V NO: 00

COMPAN

nce certificat

ters etc. shae.

guidelines

ustomer holpection/ testirecords etc. ed compone

bject to BHEr reference p

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for same incand if some

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ed separatel

402-155A-A001

DATE:

NY SEAL

te and furnis

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given in the

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Page 490 of 495

NA

I …pefor I ab B AS N B

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AME

………………rtaining to trmat proposa

hereby certbove my sig

idders Com

uthorized reignature

ame

idder’s Nam

he bidder hedicated.

PARTICU DESIGN

TITLE:

ST

………………his specifica

al number Da

tify that I amgnature.

mpany Name

epresentativ

me

ereby agree

ULARS OF BIDD

NATION

BHEL

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TEAM TURBIN2X5

………………ation are coated …………

m duly auth

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all the tecf the equipm

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intent of this

EC NO: PE-TS-4

LUME: III

CTION:

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COMPAN

chnical data ment/systemcation.

any whose

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s specificat

402-155A-A001

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Page 491 of 495

SL NO

VOULME/ SECTION

PAGE NO.

CLAUSE NO.

TECHNICAL SPECIFICATION/

TENDER DOCUMENT

COMPLETE DESCRIPTION OF DEVIATION

COST OF WITHDRAWL

OF DEVIATION

REFERENCE OF PRICE

SCHEDULE ON WHICH COST OF WITHDRAWL OF

DEVIATION IS APPLICABLE

NATURE OF COST OF

WITHDRAWL OF DEVIATION (POSITIVE/ NEGATIVE)

THIS IS A PART OF TENDER TECHNICAL SPECIFICATION PE-TS-402-155A-A001

13. In case nature of cost of withdrawl (positive/negative) is not specified it shall be assumed as positive.

14. In case of descrepancy in the nature of impact (positive/ negative), positive will be considered for evaluation and negative for ordering.

11. All techno-commercial terms and conditions of NIT shall be deemed to have been accepted by the bidder, other than those listed in unpriced copy of this format.

PARTICULARS OF BIDDERS/ AUTHORISED REPRESENTATIVE

12. Cost of withdrawl is to be given seperately for each deviation. In no event bidder should club cost of withdrawl of more than one deviation else cost of withdrawl of such deviations which have been clubbed together shall be considered as NIL.

REASON FOR QUOTING DEVIATION

SCHEDULE OF DEVIATIONS WITH COST OF WITHDRAWL

PROJECT:-STEAM TURBINE GENERATOR AND AUXILIARIES (NTA 2)2X500 MW NEW NEYVELI TPP

PACKAGE:-CONDENSATE POLISHING UNIT

NAME OF VENDOR:-

TECHNICAL DEVIATIONS

COMMERCIAL DEVIATIONS

TENDER ENQUIRY REFERENCE:-

10. Any deviation mentioned in priced copy of this format, but not mentioned in the un-priced copy, shall not be accepted.

NAME DESIGNATIONS SIGN & DATE

NOTES:

1. For self manufactured items of bidder, cost of withdrawl of deviation will be applicable on the basic price (i.e. excluding taxes, duties & freight) only.

2. For directly dispatchable items, cost of withdrawl of deviation will be applicable on the basic price including taxes, duties & freight.

9. For deviations w.r.t. Payment terms, Liquidated damages, Firm prices and submission of E1/ E2 forms before claiming 10% payment, if a bidder chooses not to give any cost of withdrawl of deviation loading as per Annexure-VIII of GCC, Rev-06 will apply. For any other deviation mentioned in un-priced copy of this format submitted with Part-I bid but not mentioned in priced copy of this format submitted with Priced bid, the cost of withdrawl of deviation shall be taken as NIL.

8. Bidders to note that any deviation (technical/commercial) not listed in above and asked after Part-I opening shall not be considered.

3. All the bidders have to list out all their Technical & Commercial Deviations (if any) in detail in the above format.

4. Any deviation not mentioned above and shown separately or found hidden in offer, will not be taken cognizance of.

5. Bidder shall submit duly filled unpriced copy of above format indicating "quoted" in "cost of withdrawl of deviation" column of the schedule above along with their Techno-commercial offer, wherever applicable.

6. Bidder shall furnish price copy of above format along with price bid.

7. The final decision of acceptance/ rejection of the deviations quoted by the bidder shall be at discretion of the Purchaser.

Page 1 of 1

Page 492 of 495

THIS IS PRAT OF TECHNICAL SPECIFICATION PE-TS-402-155A-A001

PROJECT: STEAM TURBINE GENERATOR AND AUXILIARIES (NTA 2)2X500 MW NEW NEYVELI TPP

SUGGESTIVE PRICE SCHEDULE

CONDENSATE POLISHING UNIT

THE PRICES SHOULD BE SUBMITTED IN THE ENCLOSED PRICE SCHEDULEFORMAT ONLY. FOLLOWING PRICE SCHEDULE FORMATS ARE ENCLOSED

ANNEXURE ‘A’ : LUMP SUM PRICES AND MAJOR

BREAK-UP OF PRICES

Name Designation Signature Date Company seal

Bidder shall furnish this price schedule in his price offer only

Particulars of bidder / authorised representative

Page 493 of 495

THIS IS PRAT OF TECHNICAL SPECIFICATION PE-TS-402-155A-A001

1 Total lump sum firm price on FOR site basis for design, engineering, manufacture,fabrication, assembly, inspection / testing at vendor's & sub-vendor’s works,painting,mandatory spares alonwith spares for errection,startup and commissioning asrequired, forwarding, proper packing, shipment and delivery at site,unloading,handling,transportation & storage at site , in site transportation, assembly, erection &commissioning, trial run on FOR site basis preparation and submission of “As Built”drawings and carrying out performance tests at site etc. inclusive of all prevailing taxes,duties and other levies and handover in flawless condition of CONDENSATE POLISHINGUNIT and external regeneration system to the end customer complete with all accessoriesfor the total scope defined as per BHEL tender technical specification (PE-TS-391-155A-A001) for project STEAM TURBINE GENERATOR AND AUXILIARIES (NTA 2),2X500MW NEW NEYVELI TPP

a) Bidder to note that total price indicated above at 1 shall be considered for evaluation andhence should be complete in all respect for the full scope defined and considering all termsand conditions agreed.

b) In case, price indicated above does not match with item wise break-up given at 2, thehighest price so calculated shall be considered for evaluation but in case of order, the sameshall be placed at the lowest price.

2 MAJOR BREAK-UP OF PRICES GIVEN IN 1 ABOVE

2.1 Total lumpsum firm price for EQUIPMENT (SUPPLY, DESIGN & ENGINEERING)i.e.manufacture, fabrication, assembly, inspection / testing at vendor's & sub-vendor’sworks, painting,mandatory spares alonwith spares for errection,startup and commissioningas required, forwarding, proper packing, shipment and delivery at site, inclusive of all taxes& duties for the complete scope of supply of CONDENSATE POLISHING UNIT andexternal regeneration system to the end customer complete with all accessories for thetotal scope defined as per tender technical specification (PE-TS-402-155A-A001).

2.2 Total lump sum firm price for all services including unloading, handling,transportation &storage at site , in site transportation, assembly, erection & commissioning, trial run onFOR site basis preparation and submission of “As Built” drawings, etc, required forcompletion of CONDENSATE POLISHING UNIT as per tender technical specification (PE-TS-402-155A-A001).

2.3 Price for performance test and handing over the plant to the customer.

3.0 Break-up (%) of prices given at Sl No-2.1 above (To be used during contract execution forpayment).

3.1 Lumpsum firm price for supply of Service vessels inclusive of all taxes, duties and otherlevies as applicable.

3.2 Lumpsum firm price for supply of Pressure vessels other than Service vessels inclusive ofall taxes, duties and other levies as applicable.

3.3 Lumpsum firm price for supply of Resin inclusive of all taxes, duties and other levies asapplicable.

3.4 Lumpsum firm price for supply of Atmospheric tank inclusive of all taxes, duties and otherlevies as applicable.

3.5 Lumpsum firm price for supply of Low Pressure Valves inclusive of all taxes, duties andother levies as applicable.

3.6 Lumpsum firm price for supply of High Pressure Valves inclusive of all taxes, duties andother levies as applicable.

3.7 Lumpsum firm price for supply of Instruments & Analyser inclusive of all taxes, duties andother levies as applicable.

3.8 Lumpsum firm price for supply of Rotary Equipments (Pumps,Blowers,Agitators etc.)inclusive of all taxes, duties and other levies as applicable.

3.9 Lumpsum firm price for supply of Piping & Fittings inclusive of all taxes, duties and otherlevies as applicable.

3.10 Lumpsum firm price for supply of PLC inclusive of all taxes, duties and other levies asapplicable.

3.11 Lumpsum firm price for supply of Balance items inclusive of all taxes, duties and otherlevies as applicable.

Name Designation Signature Date Company seal

10% of sl no 2.1 above.











Bidder shall furnish this price schedule in his price offer only

Particulars of bidder / authorised representative

ANNEXURE -A

Page 494 of 495

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-402-155A-A001

S.NO. DESCRIPTIONS UNIT TOTAL CIF CONTENT

1) Resins

ANNEXURE-B

LIST OF CIF CONTENTS FOR CONDENSATE POLISHING UNIT FOR STEAM TURBINE GENERATOR AND AUXILIARIES (NTA 2)

2X500 MW NEW NEYVELI TPP

Page 495 of 495

2x500 MW, NNTPP, Neyveli CONTRACT · PDF file2x500 MW, NNTPP, Neyveli CONTRACT SPECIFICATION...

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